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Modular Process Systems & Skids

Distillation Column Design

Separation of your chemicals requires distillation columns that are expertly designed to achieve separation without added expense. Designers must size equipment correctly for your process to be successful. We have over 20 years of proven industrial column design & fabrication experience. Our engineers are experts in sizing, mechanical design, system modeling, and practical design for manufacturing environments.

EPIC Systems combines design, engineering, fabrication and integration to a single point of turn key project responsibility. We take your separation technology and use our proven engineering methods to model it for separation feasibility at desired production rates.

Case Studies of Proven Industrial Distillation Columns


Pilot Scale System with Industrial Distillation Equipment Achieves 90% CO2 Sequestration

A modular distillation skid design allowed safe and timely off-site construction of a pilot-scale distillation skid. The pilot plant is testing an experimental new technology for CO2 removal from power plant flue (or exhaust) gas. CO2 was removed from flue gas in a two-step distillation process with solvent reclamation. Read the full CO2 Sequestration from Coal Fired Flue Gas case study…

Key Features: Modular skid weighing 39,000 lbs and standing 51 feet tall, dual packed distillation units, DeltaV DCS, Class 1, Div 1

Read Full Case Study

A Dual Skid Continuous Distillation System Provides Compact Solution

A two-part design was developed for an ethanol extraction system that needed to fit into a small space as part of EPIC’s turnkey responsibility process.  Overall project timeline shortened due to on-site upgrades and skid fabrication progressing in tandem. The finished “plug and play” skid was delivered as two separate framed pieces to the client site and successfully navigated to the installation spot. Continue to the Innovative Distillation Skid Design case study…

Key Features: Two distillation units, reflux loops, hot oil system, heat exchanger, hydrotesting, FEA analysis, vacuum pump system to lower required energy inputs.

Read Full Case Study

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What Do I need to Know to Get Column Pricing?

You don’t need to know anything to contact us and start working with one of our distillation experts.

However, you will need to know some information about the process objectives you are trying to achieve before you can get accurate pricing or start column design. Basic information usually consists of:

  1. Properties of your distillation feed, including:
    1. Composition:
      1. Solids?
      2. Non-condensables?
      3. Azeotropes?
    2. Feed rate and temperature
    3. Materials of Construction
  2. The desired heating and cooling mediums
  3. The operating temperature range you wish to achieve during heating, separation and cooling
  4. Your target operating pressure range during heating, separation and cooling
  5. Desired end product specifications
    1. Chemical composition
    2. Purity requirements
  6. Recycle and waste stream properties, including:
    1. Acceptable stream composition?
    2. Will further processing be required?

Don’t know all of this yet? That’s okay. Just contact us and tell us what you do know and we can help you through the rest.

View more distillation systems and plants in our photo gallery

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Column Cost Spec Sheet

This planning guide covers the areas that drive costs on a distillation columns design project. To get pricing, you will need an engineering or column design firm to help you specify the areas outlined in this guide, include:

  • Process operating parameters
  • Key feed composition properties
  • Instrumentation selection
  • Additional processing scope
  • Utilities
  • And more

Also included is a guide to distillation column design factors, such as flood ratio, jet flood, reflux ratio, etc.

Download the full cost planner below. An experienced distillation column designer can help you fill out the planner and determine project scope. Please contact EPIC 314-845-0077 to talk to one of our distillation experts.

Print PDF Version

The EPIC Distillation Column Checklist is below. If you have any questions or need any help planning your process skid, please contact an engineer or call us at 314-310-1549.

Distillation Column Design Checklist

The checklist to the left is a basic tool you can use to vet your column design and make sure it is accurate. Walk through the questions with your column design vendor or in-house staff and make sure these major areas correctly addressed to ensure a solid design.

Distillation column design is an iterative process. If you find a hole in the plan on the first review, revisit the design assumptions, operating parameters and re-run the model. Design decisions are usually based around trade-offs, so it’s always a good idea to re-run through this checklist to make sure you haven’t accidentally compromised a basic operating condition.

For a more detailed explanation of distillation column design, checkout the download below:

A Proven Approach to Distillation Column Design

EPIC Modular Process Systems guides your systems from initial concept to complete startup through all phases of:

  • Industrial Fractionating System Design
    • Simulation software is used to iterate a proposed separation strategy
    • Mass and energy balances are calculated accurately
    • Physical plant design is completed using 3-D CAD software.
  • Equipment Specification and Procurement
    • Detailed P&IDs are developed for the industrial fractionating system
    • Equipment and instrumentation is specified and compared across several vendors
    • Equipment is ordered in congruence with project timeline and equipment lead time
  • Process Automation
    • EPIC’s controls engineers design a robust and intuitive control system strategy to automate the system
    • System programming and electrical wiring is completed in parallel with equipment assembly and fabrication
  • Distillation System Fabrication 
    • Column fabrication happens inside EPIC’s state-of-the-art machine shop
    • Quality assurance checks are performed throughout the fabrication and assembly process
    • Complete system is fully tested per ASME requirements
  • Plant Construction Management
    • EPIC oversees and actively manages site civil and facilities engineering
    • Site civil and facility modifications occur in parallel with distillation tower fabrication in the EPIC fabrication plant
  • Onsite System Installation
    • Completed modules are insured, packaged, and shipped to our client’s manufacturing sites where installation is supervised by EPIC’s experienced project managers

We strive to take the burdens of project management from our clients, regardless of the industry, to apply innovative technology and dedicated project oversight.

Contact EPIC Modular Process Systems to learn more or to discuss how we can help you meet your manufacturing objectives with a custom fractional column design.

Key Advantages Provided by EPIC on Distillation Projects

Our experienced control & mechanical engineering teams will design, manage and integrate the proper instrumentation and controls for each fractionating column. Our skilled manufacturing crew will utilize proven designs to fabricate and then test modular skids that will minimize installation time and condense space. We are an experienced distillation column manufacturer, with in-house ASPEN Plus & HYSYS modeling, fabrication and controls integration capabilities.

  • Flexibility of Equipment Integration

One size does not fit all, and our modular fractionation columns are integrated with any equipment or existing application. We build a wide variety of reliable resources for the best equipment solution, regardless of vendor, and work with you or other engineering and fabrication companies on any stage of your project. We utilize our proprietary modular process approach to integrate your modular distillation system design faster, with the elimination of plant shut downs through the use of our parallel construction techniques

  • Proven Engineering During The Design Phase

Integrating the proper equipment and distillation column design should be carefully reviewed by skilled process engineers before building a full scale plant. Cost, chemical interactions and equipment needs change as larger output is required. Critical factors must be determined during the design phase, such as; boiling point elevation, surface tension, solubility, maximum achievable concentration

  • Advantages to Modular Design

Our modular fabrication approach to fractionation column has many advantages, including; reduced costs, higher quality fabrication, faster time to market, improved safety, less resource requirements, flexibility. To learn specifically how modular fabrication achieves these benefits, please visit our Advantages of Modular Fabrication page.Reduced cost

EPIC specializes in taking your specifications and turning them into a complete system from concept to start up. We have a wide variety of experiences in Pilot Plant and Production Plant scale-up.

Blog

Featured Blog/Article

 

A Stepwise Procedure for Continuous Column Design

 

Steps qualified engineers should consider when designing a distillation column…

Blog

Featured Blog/Article

 

Five Critical Factors to Vapor-Liquid Equilibrium During Distillation

 

Understand the factors that affect vapor-liquid equilibrium.

Blog

Featured Blog/Article

 

8 Key Challenges to Scale-up

 

Read about scale up challenges and how to overcome them…

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EPIC Modular Process Systems
4134 Meramec Bottom Rd
St. Louis, MO 63129, US
(314) 845-0077